5000TQ Avant Starting Problems

[Stephen Sherman]

Thanks for the part number and link. That is probably the way to go.

IIRC the amount of twisting was minimal. maybe 5-10 degrees of twist 
between the two ends put it back to its original configuration. The part 
just seemed to take on a twist a bit over the years of use. Done over 
several persuasive twists back, a little at a time it went back just 
fine. (Would not put this in a vise and try to correct it all at once)  
At the time, 10 years ago, I did that because it was quicker than 
ordering and waiting on a new part. It did hold up for as long as I 
owned the car (another 5 years) so seemed to be a decent fix.

BTW- this morning at -5F the car started no problem, and continued to do 
so all day while running errands in fairly cold temps. First time it has 
started below 10F in a couple of months. So it would seem that this was 
the key to the problem.

I will check out the cable splice too, as I recall seeing some headlight 
dimming on occasion, which  I think points to a splice issue.

Thanks for all the help on this.



Steve Sears wrote:
> Oooorrr, instead of tempting fate trying to bend the pot metal piece.....how 
> about $10.17 plus shipping for part number 443905855A ?  The link is at:
> http://europartsamerica.com/parts/product_details/443905855A
> Getting the old switch out involves a bit of precisely located drilling on 
> the steering column lock casting to push a retaining spring in.  The new 
> unit comes with a set of keys, but if you want to retain your original keys 
> you can carefully drive out the roll pin that connects the pot metal piece 
> to the lock cylinder and swap cylinders.
> I ordered said piece because the starter was becoming flaky - even on a 
> reasonably full battery.  As it turned out, the culprit was the splice in 
> the main battery cable running from the starter to the battery - when under 
> a heavy load - ie, when the starter was engaged - the cable at the splice 
> would heat up nicely....enough to carbonize the insulation and scorch the 
> wire within 10" of the splice. 
> http://gallery.quattroworld.com/d/9160-2/Img_4660_1.jpg
> Replaced the cable with #2 welding cable to the starter and she's been 
> starting like a dream ever since.
> Cheers!
> Steve Sears
> 1987 Audi 5kTQ
> 1980 Audi 5k
> 1962 and '64 Auto Union DKW Junior deLuxes
> ----- Original Message ----- 
>   
>> Date: Tue, 09 Feb 2010 09:36:06 -0800
>> From: "john at westcoastgarage.net" <john at westcoastgarage.net>
>> Subject: Re: Re: 5000TQ Avant Starting Problems
>> To: Stephen Sherman <spsherm at msn.com>
>> Cc: Robert Myers <robert at s-cars.org>, quattro at audifans.com, Tony
>> Hoffman <auditony at gmail.com>
>> Message-ID: <4B719D06.20408 at westcoastgarage.net>
>> Content-Type: text/plain; charset=ISO-8859-1; format=flowed
>>
>> Stephen Sherman wrote:
>>     
>>> <div class="moz-text-flowed" style="font-family: -moz-fixed">One other
>>> thought. ~10 years ago on another 5000TQ Avant we had, I vaguely
>>> recall a repair to the ignition switch that I did. IIRC there is a
>>> shaft that connects the ignition lock tumbler to the electrical
>>> switch, and over time that shaft twists some.  The repair was to twist
>>> the shaft back a bit to get it closer to its original alignment.
>>>
>>> This ring any bells with anyone? I no longer recall the symptoms this
>>> had, but if it causes the electrical switch to not rotate far enough
>>> into the start position, seems like it may be related...
>>>
>>> </div>
>>>
>>>       
>> That shaft is pot metal.  Twisting = breaking.  John
>>     
>
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